Heat exchanger assemblies and methods for cooling the interior of an enclosure

ABSTRACT

Heat exchanger assemblies and methods are provided for cooling the interior of an enclosure (e.g., electrical cabinets, computer server racks, chemical chambers, and animal cages). Heat is transferred via thermal conduction from a first plurality of surfaces positioned inside the enclosure to a second plurality of surfaces positioned outside the enclosure. The first and second plurality of surfaces remain in thermal contact with one another during use. Heat is dissipated from the second plurality of surfaces to the ambient air outside the isolated environment without the ambient outside air mixing together with the air inside the enclosure. This, in turn, inexpensively removes heat from the air inside the enclosure and prevents contaminants from entering the enclosure.

CROSS-REFERENCES TO RELATED APPLICATIONS

This application is a divisional of U.S. patent application Ser. No.15/642,209, filed Jul. 5, 2017, entitled “HEAT EXCHANGER ASSEMBLIES ANDMETHODS FOR COOLING THE INTERIOR OF AN ENCLOSURE,” the entire contentsof which are herein incorporated by reference for all purposes.

BACKGROUND

Many activities release thermal energy (i.e., heat). Examples includemechanical (e.g., friction), chemical (e.g., exothermic reactions),biological (e.g., endothermic organisms), and electrical activities(e.g. electronic components). When heat is generated in a closedenviron, it presents unique challenges when cooling is desired insidethe enclosure. Such challenges extend to include many sizes of closedenvironments including sealed cabinets, closets and even secured rooms,for example.

Over-heating of computer components due to the heat generated byelectrical equipment itself continues to be a significant problem.Electrical equipment that overheats can malfunction and set fire, whichis costly and dangerous.

Despite the progress made in the area of thermal and mechanical systems,there is a need in the art for improved methods and systems related tothermal and mechanical systems.

SUMMARY

The present invention relates generally to cooling the inside of anenclosure. Heat exchanger assemblies and methods are provided forcooling the interior of an enclosure where heat is transferred viathermal conduction from a first plurality of surfaces positioned insidethe enclosure to a second plurality of surfaces positioned outside theenclosure. The first and second plurality of surfaces remain in thermalcontact with one another during use. Heat is dissipated from the secondplurality of surfaces to the ambient air outside the isolatedenvironment without the ambient outside air mixing together with the airinside the enclosure. This, in turn, inexpensively removes heat from theair inside the enclosure and prevents contaminants from entering theenclosure.

According to an embodiment of the present invention, a heat exchangerassembly operably transfers heat from inside air located inside a closedcontainer to outside air located outside the closed container. The heatexchanger assembly comprises an interior thermal conductor. The interiorthermal conductor comprises an interior core joined to an interior sideof the closed container and a first plurality of surfaces. The firstplurality of surfaces are joined to the interior core and the firstplurality of surfaces are spaced apart from one another. An exteriorthermal conductor comprises an exterior core joined to an exterior sideof the closed container; and a second plurality of surfaces are joinedto the exterior core. The second plurality of surfaces are spaced apartfrom one another. A thermal path is defined from the first plurality ofsurfaces to the second plurality of surfaces. It's important to notethat the inside air does not mix with the outside air.

According to another embodiment of the present invention, a method ofremoving heat from an isolated environment comprises first providing anisolated environment. The environment contains a heat producing item andis configured to seal ambient air inside. A heat exchanger assembly isaffixed to a partition of the isolated environment. The heat exchangerassembly comprises a first plurality of spaced, substantially parallelfins, and a second plurality of spaced, substantially parallel finswhich are provided opposite the first plurality of fins such that thefirst plurality of fins are in thermal contact with the second pluralityof fins across a solid substrate core. At least one first fan isoperatively connected to the solid substrate core and the firstplurality of fins. At least one second fan is operatively connected tothe solid substrate core and the second plurality of fins. Power issupplied to the at least one first and second fans and the at least onefirst fan is used to push ambient air inside the isolated environmentacross the first plurality of fins. The at least one second fan is usedto push ambient air outside the isolated environment across the secondplurality of fins to allow conductive heat transfer from the firstplurality of fins to the second plurality of fins to remove heat fromthe isolated environment during use without the air outside the isolatedenvironment from mixing with the air inside the isolated environment.The ambient air inside the isolated environment is warmer than theambient air outside the isolated environment.

According to yet another embodiment of the present invention, a heatexchanger assembly operably transfers heat from inside air locatedinside a closed container to outside air located outside the closedcontainer. The heat exchanger assembly comprises an interior thermalconductor comprising a first plurality of surfaces joined to a firstside of a central core. The first plurality of surfaces are spaced apartfrom one another. An exterior thermal conductor comprises a secondplurality of surfaces joined to a second side of the central core andthe second plurality of surfaces are spaced apart from one another. Athermal path is defined from the first plurality of surfaces to thesecond plurality of surfaces and the inside air does not mix with theoutside air during use.

Numerous benefits are achieved by way of the present invention overconventional techniques to cool enclosures. For example, embodiments ofthe present invention provide effective, inexpensive, reliable,versatile, and efficient heat exchangers and methods for removing heatfrom isolated environments, including closed containers that resistperformance degradation over time, have a long life span; operate over awide temperature range, prevent contaminants from entering theenclosure, mitigates thermal gradients, and have a compact, lightweightdesign. Moreover, embodiments of the present invention provide coolingwithout using dangerous chemicals or cooling fluids that harm theenvironment. Furthermore, the heat exchanger can be used indoors oroutdoors and can be scaled to the enclosure size. It can also beinstalled in a variety of locations and orientations.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is cross-sectional view of a heat exchanger assembly according toan embodiment of the present invention.

FIG. 2A is a cross-sectional view of a heat exchanger assembly accordingto another embodiment of the present invention.

FIG. 2B is a cross-sectional view of a heat exchanger assembly accordingto another embodiment of the present invention.

FIG. 3 is a front view of an enclosure showing heat exchanger assembliesinstalled in four different locations according to an embodiment of thepresent invention.

FIG. 4 is a view of an enclosure showing four heat exchanger assembliesinstalled at four different locations with different exemplaryorientations according to embodiments of the present invention.

FIG. 5 is a flow diagram according to an embodiment of the presentinvention.

FIG. 6A is an exploded view of some components of the heat exchangerassembly according to an embodiment of the present invention.

FIG. 6B is a view similar to FIG. 6A including the fans.

FIGS. 7A-7G is a diagram showing examples of a plurality of surfaceconfigurations according to other embodiments of the present invention.

FIG. 8 is a graphical representation showing performance vs. sizecomparison of selected types of heat exchangers according to anembodiment of the present invention.

FIG. 9 is a graphical representation showing performance vs. costcomparison of selected types of heat exchangers according to anembodiment of the present invention.

DETAILED DESCRIPTION OF SPECIFIC EMBODIMENTS

Certain embodiments of the invention effectively and efficientlyfacilitate cooling the interior of a substantially airtight enclosureusing principles of thermal conduction. A plethora of scalableconfigurations and installation orientations of the heat exchangerassembly are contemplated to cool a variety of enclosure sizes. In someembodiments, the fins have spacing, height, and thickness sized to fit aperformance curve of each of the connected fans. The fans may beconnected to a programmable thermostat.

To avoid over-heating inside an enclosure, a wide variety of techniquesare employed to maintain at least an ambient temperature within theenclosure. Historically, there are four common ways to remove heat fromenclosures. These include natural convection, compressed air, heat pipesand air conditioners.

Natural convection relies on fans and filters and is inexpensive tooperate; however, natural convection only works when the ambient air iscool and clean. If the air is not clean, the fan will introduce airbornecontaminants into the enclosure. Unfortunately, most facilities andenclosures do not have an adequate supply of naturally cool and cleanair. Therefore, natural convection is not commonly used to remove heatfrom enclosures.

Compressed air coolers use a small stream of air that passes through acooler. A vortex is created to reduce the heat. They are capable ofcooling below ambient temperatures; however, compressed air cooling isexpensive. Additionally, lines tend to become blocked when compressedair coolers are used in harsh environments and they tend to introducedust and other contaminants into enclosed spaces. They also tend to emita small amount of oil mist from the lines into the enclosure. Without asource of compressed air, this method of cooling will not work.

Heat pipes have the potential to cool an enclosure at slightly aboveoutside ambient air temperatures; however, the installation of heat pipeexchangers can be costly and is limited to very specific placement andorientation. They require fluids and tend to suffer from performancedegradation and reliability issues over time.

Air conditioning to cool an enclosure is expensive and uses significantamounts of energy. Another drawback is that many air conditioners stilluse Freon®, a chlorofluorocarbon (CFC). The U.S. EnvironmentalProtection Agency has declared chlorofluorocarbons to be potentiallydamaging to the ozone layer of the earth's atmosphere. Freon® may causeillness and the vapors can cause asphyxiation in confined spaces.

Information related to attempts to address these problems can be foundin U.S. Pat. Nos. 4,706,739; 4,907,644; 5,297,005; 5,311,928; 5,406,451;5,579,830; 5,748,445; 6,105,875; 6,131,647; 6,196,003; 6,301,779;6,611,428; 7,342,789; 7,436,660; 7,650,932; 7,654,310; 7,957,132; andUnited States Patent Application Publication Numbers: 2011/0267776 A1and 2015/0075184 A1; as well as the following publications: Dawn, K.,Reduce Electronic Waste Heat Without Breaking The Budget, IMPO (April2012) pp. 22-23; and Lienhard, J. H., et al., A Heat Transfer Textbook,Dover Civil and Mechanical Engineering, 4th Edition (2011) pp. 6-10,99-129, 141-184, for example. Various types of systems, devices,assemblies and methods for removing heat from an isolated environment orassociated technologies, including some embodiments of the subjectinvention, can mitigate or reduce the effect of, or even take advantageof, some or all of these potential problems and shortcomings.

For at least the foregoing reasons, there's a legitimate need foreffective, inexpensive, reliable, versatile, and efficient heatexchangers and methods for removing heat from isolated environments,including closed containers, without the drawbacks previously described.It would be preferable that the heat exchanger also: 1) resistsperformance degradation over time; 2) has a long life span; 3) operatesover a wide temperature range; 4) prevents introduction of contaminantsinto the enclosure; 5) mitigates thermal gradients (i.e., hot spots); 6)has a compact, lightweight design; 7) does not use dangerous chemicalsor cooling fluids; 8) does not harm the environment; 9) can be usedindoors or outdoors; 10) can be scaled to the enclosure size; and 11)installs easily in a wide variety of locations and orientations. Powersavings and reduced operating costs would also be welcome advantages.

FIG. 1 is cross-sectional view of a heat exchanger assembly 100according to an embodiment of the present invention. The heat exchangerassembly 100 transfers heat in direction 101 from relatively warm air102 located inside a closed container 103 to relatively cooler air 104located outside the closed container 103. The heat exchanger 100assembly has an interior thermal conductor that includes an interiorcore 105 joined to an interior side 115 of the closed container and afirst plurality of surfaces 106 joined to the interior core 105. Thefirst plurality of surfaces 106 are spaced apart from one another. Thereis also an exterior thermal conductor that includes an exterior core 107joined to an exterior side 116 of the closed container and a secondplurality of surfaces 108 joined to the exterior core 107. Optionally,gaskets may be installed between the interior core 105 and the interiorside 115 of the container and/or between the exterior core 107 and theexterior side 116 of the closed container 103 to seal the closedcontainer such that no inside air 102 is mixed with outside air 104.Like the first plurality of surfaces 106, the second plurality ofsurfaces 108 are also spaced apart from one another. The first pluralityof surfaces may have a darker color (e.g., a lower relative reflectanceand/or increased heat absorption) relative to the color of the secondplurality of surfaces. The second plurality of surfaces may have arelatively higher reflectance and/or decreased heat absorption. Thiscolor differential may enhance a thermal pathway between the surfaces. Athermal path 109 is defined from the first plurality of surfaces 106 tothe second plurality of surfaces 108. The thermal path 109 includes anarea of heat transfer by conduction. The inside air 102 does not mixwith the outside air 104. Cooler air moves in directions 110, 111, 112and relatively warmer air moves in directions 101, 113, 114.

According to some embodiments of the present invention, the interiorcore 105 and the exterior core 107 are positioned substantially oppositeone another across the interior side 115 and exterior side 116 of theclosed container 103. The first and/or second plurality of surfaces maybe fins, pins, pegs, or any combination thereof. The first and/or secondplurality of surfaces are configured to be attached to the interiorand/or exterior cores in any combination of straight, flared, angled,offset, or random arrangement, for example. The heat exchanger assembly100 further comprises at least one first fan operatively connected tothe interior core. The at least one first fan is configured to move airacross the first plurality of surfaces and at least one second fan isoperatively connected to the exterior core. The at least one second fanis configured to move air across the second plurality of surfaces. Eachof the first plurality of surfaces and the at least one first fan onlycontacts the inside air located inside the closed container while thesecond plurality of surfaces and the at least one second fan onlycontacts outside air located outside the closed container. The firstplurality of surfaces may have a darker color relative to the color ofthe second plurality of surfaces.

Heat is transferred via thermal conduction from the first plurality ofsurfaces to the second plurality of surfaces during use to cool theinside air located inside the closed container and dissipate heat fromthe second plurality of surfaces to the outside air located outside theclosed container. The heat exchanger assembly does not employ anyfluids, coolants or refrigerants during use.

According to embodiments of the present invention, the closed containercontains a heat generating item. For example, the heat generating itemmay include heat from electrical activity, mechanical activity, chemicalactivity, biological activity, radiant activity, or any combinationthereof. The first plurality of surfaces and the second plurality ofsurfaces have a spacing, a height, and a thickness sized to fit aperformance curve of each of the at least one first and second fans,respectively. The spacing may be between about 0.03 and 0.125 inches,the height is between about 0.5 and 2.5 inches, and the thickness isbetween about 0.001 and 0.1 inches, for example. The first and secondplurality of surfaces may be made of aluminum, copper, steel, or alloysthereof. The assembly substantially mitigates temperature gradientsinside the closed container.

According to embodiments of the present invention, at least one firstand second fans may have the same capacity or they may have differentcapacities. The at least one first fan may have a capacity of about 150cubic feet per minute and the at least one second fan may have acapacity of about 150 cubic feet per minute, for example. The firstplurality of surfaces are about 0.04 inches thick and the secondplurality of surfaces are about 0.04 inches thick. The first pluralityof surfaces and the at least one first fan are capable of transferringat least 300 watts of heat from the (relatively warmer) inside airlocated inside the closed container to the outside air located outsidethe closed container when the inside air located inside the closedcontainer is approximately 20° Celsius above the temperature of theoutside air located outside the closed container. The heat exchangerassembly is configured to attach to the closed container in a variety ofways including vertical, horizontal, or diagonal orientations. The heatexchanger has a temperature rating between 1° Celsius and 70° Celsiusand can operate effectively in both indoor and outdoor environments.

The interior core 105 and the exterior core 107 are positionedsubstantially opposite one another across the interior side 115 andexterior side 116 of the closed container 103 as shown in FIG. 1.Alternatively, the interior core 105 and exterior core 107 may bepositioned offset from one another. Provided that at least some of thefirst and second plurality of surfaces define a thermal pathway acrossthe surfaces, they may be offset to some degree. For example, the first206 and second 208 plurality of surfaces are offset across a centralcore 205 in FIG. 2A. Alternatively, FIG. 2B shows the first 206 andsecond 208 plurality of surfaces positioned substantially opposite andin alignment with one another across the central core 205. Generally,the larger the thermal pathway, the greater the potential to removeheat.

As shown in FIG. 2A, a heat exchanger assembly 200 operates to transferheat from inside air 202 located inside a closed container 203 tooutside air 204 located outside the closed 203 container. The heatexchanger assembly 200 includes an interior thermal conductor comprisinga first plurality of surfaces 206 joined to a first side 215 of acentral core 205, wherein the first plurality of surfaces 206 are spacedapart from one another. An exterior thermal conductor comprises a secondplurality of surfaces 208 joined to a second side 216 of the centralcore 205. The central core 205 may be a wall, door, or partition of theclosed container 203, for example. The second plurality of surfaces 208are spaced apart from one another. A thermal path 209 is defined fromthe first plurality of surfaces 206 to the second plurality of surfaces208. Conductive heat transfer occurs across the thermal path 109, 209per FIGS. 1 and 2A, respectively. The inside air 202 does not mix withthe outside air 204 during use. This prevents particulates (e.g., dust,debris, foreign matter) from entering the closed container thus avoidingcontaminating the items inside the closed container while keeping themrelatively cool. Cooler air moves in directions 210, 211, 212 andrelatively warmer air circulates in direction 201, 213, 214.

The heat exchanger system 100 may also be comprised of at least onefirst fan 117 operatively connected to the interior core 105 to move air102 across the first plurality of surfaces 106 in direction 101. Atleast one second fan 118 is operatively connected to the exterior core107 to move air 104 across the second plurality of surfaces 108 indirection 110. The mechanical movement of air via fan facilitates theconductive heat transfer across the thermal pathway and may addefficiency to the removal of heat, for example. Of course, more fans maybe added/coupled to the heat exchanger system based on the size of theclosed container, the amount of heat to be removed, the temperaturegradient inside vs. outside the closed container, and many otherfactors. In any event, each of the first plurality of surfaces and theat least one first fan only contacts the inside air located inside theclosed container and the second plurality of surfaces and the at leastone second fan only contacts outside air located outside the closedcontainer such that heat is transferred via thermal conduction from thefirst plurality of surfaces to the second plurality of surfaces duringuse. As relatively warm air moves in direction 101 across the firstplurality of surfaces 106, the air is conductively cooled as heat movesacross the thermal pathway 109. Relatively cooler air moves indirections 111 and 112. Heat is dissipated from the second plurality ofsurfaces 108 to the outside air 104 in directions 113 and 114. Thisprocess does not require the use of any fluids, coolants orrefrigerants. No liquids are used. The location of the closed containermay cause the inside air 102 to be relatively warmer that the outsideair 104. In addition or alternative to radiant energy warming the insideof the container, the closed container may contain a heat generatingitem. This item could be electronics (e.g., computer or stereoequipment) or even an exothermic chemical reaction or warm bloodedanimal, for example. Therefore, the heat generating item may includeheat from electrical activity, mechanical activity, chemical activity,biological activity, radiant activity, or any combination thereof. Insome regards, the larger the temperature difference between the outsideand the inside of the closed container, the more pronounced thepotential heat removal. Even a small temperature difference allows theheat exchanger assembly to substantially mitigate temperature gradientsinside the closed container.

The first plurality of surfaces 106 and the second plurality of surfaces108 of the heat exchanger assembly 100 may be made of aluminum, copper,steel, or metal alloy and have a spacing, a height, and a thicknesssized to fit a performance curve of each of the at least one first 117and second 118 fans, respectively. The spacing is between about 0.03 and0.125 inches, the height is between about 0.5 and 2.5 inches, and thethickness is between about 0.001 and 0.1 inches. The fans 217, 218 andsurfaces 206, 208 shown in FIG. 2 may have a similar relationship asthose described in relation to FIG. 1.

The at least one first and second fans may have the same capacity ordifferent capacities. Usually, if fans are installed, they will have thesame capacity on each side of the container. The number of fans may bescaled according to the number of surfaces, for example. In a preferredembodiment, the at least one first fan 117, 217 has a capacity of about200 cubic feet per minute and the at least one second fan 118, 218 has acapacity of about 200 cubic feet per minute.

In another preferred embodiment, the first plurality of surfaces 106,206 are about 0.04 inches thick and the second plurality of surfaces108, 208 are about 0.04 inches thick. Of course, the thickness,material, spacing, shape, and configuration of the surfaces may varydepending on parameters of the specific cooling project at hand.Generally, the first plurality of surfaces 106, 206 and the at least onefirst fan 117, 217 are capable of transferring at least 300 watts ofheat from relatively warmer inside air 102, 204 located inside theclosed container 103, 203 to the outside air 104, 204 when therelatively warmer inside air 102, 202 is approximately 20° Celsius abovethe temperature of the outside air 104, 204.

As shown in FIG. 3, the heat exchanger assembly 300 can be attached tothe closed container 303 in a variety of locations. Top mount 301, sidemounts 304, 305 and bottom mount 302 configurations are possible withoutdegrading (or even affecting) the efficiency of the heat transfer. Sinceheat rises and heat dissipation inside a closed container is limited ornon-existent, the top mount position can generally be expected to havethe highest temperature differential (e.g., inside air temperature vs.outside air temperature). These various installation options are veryconvenient and allow flexibility for attaching the heat exchangerassembly 300 where space is limited, for example. Other types of coolingsystems do not offer this advantage. In addition, the heat exchangerassembly can be attached to the closed container 404 in a variety oforientations including vertical 401, horizontal 405, or diagonal 402,403 orientation as shown in FIG. 4. The heat exchanger assembly 400 mayhave fans (including 3 fans 418) or may not have any fans connected tothe plurality of surfaces 408 as shown in the heat exchanger assemblymounted diagonally 403, for example. Regardless of the presence ornumber of fans, the heat exchanger has a temperature rating betweenabout 1° Celsius and 70° Celsius and can operate effectively in bothindoor and outdoor environments.

FIG. 5 shows a method of removing heat from an isolated environmentaccording to an embodiment of the present invention. The method 500comprises providing an isolated environment 501. The environment (e.g.,a case, container, cabinet, closet, room, or building) contains a heatproducing item and seals ambient air inside. A heat exchanger assemblyis affixed to a partition of the isolated environment 502. The heatexchanger assembly comprises a first plurality of spaced, substantiallyparallel fins and a second plurality of spaced, substantially parallelfins positioned opposite the first plurality of fins such that the firstplurality of fins are in thermal contact with the second plurality offins across a solid substrate core. At least one first fan is connectedto the solid substrate core and the first plurality of fins. At leastone second fan is connected to the solid substrate core and the secondplurality of fins. Power is supplied 503 to the at least one first andsecond fans. The first fan(s) push ambient air inside the isolatedenvironment across the first plurality of fins and the second fan(s)push ambient air outside the isolated environment across the secondplurality of fins. This facilitates conductive heat transfer from thefirst plurality of fins to the second plurality of fins. Thus, heat isremoved from the isolated environment during use without the air outsidethe isolated environment from mixing with the (relatively warmer) airinside the isolated environment.

According to another alternative embodiment of the present invention,the method of removing heat from an isolated environment may furthercomprise utilizing a programmable thermostat that is operably attachedto the heat exchanger assembly to power the at least first and/or secondfans according to programmed temperature settings. The isolatedenvironment may be a container, a case, a cabinet, a closet, a room oreven an entire building. The heat exchanger assembly substantiallyreduces temperature gradients inside the isolated environment.

Optionally, a programmable thermostat may be employed 504. Thethermostat is attached to the heat exchanger assembly to activate powerto the at least first and/or second fans according to programmedtemperature settings. The temperature settings can be pre-programmed orentered by a user in real time, for example. Remote temperatureprogramming using a computer or smart phone via a wireless connection(e.g., Bluetooth® or Wi-Fi®) is contemplated. In this way, power isconserved and the temperature is closely regulated.

According to yet another alternative embodiment of the presentinvention, the method of removing heat from an isolated environment mayfurther comprise attaching a fan shroud to each of the at least onefirst and second fans. The fan shrouds are configured to channel airover, between, and/or around the first and second plurality of fins,respectively. Optionally, the fan shroud may be attached 505 to each ofthe at least one first and second fans to channel air over, between,and/or around the first and second plurality of fins, respectively. Thefan shroud may assist the heat exchanger assembly remove heat moreefficiently. The heat exchanger assembly, particularly with the fans andfan shrouds, substantially reduces thermal gradients/hot spots insidethe isolated environment as air is circulated in directions 101, 110across the surfaces (e.g., fins) 106, 108 exiting in directions 111, 112and 113, 114, respectively, in FIG. 1.

Referring now to FIG. 6, a heat exchanger assembly 600, minus the fans,is shown in a exploded view. A first plurality of surfaces 606 and/or asecond plurality of surfaces (not shown) are disposed on an interiorcore 605 and an exterior core (not shown) in an arrangement similar toFIG. 1. Alternatively, the plurality of surfaces may be attached to acentral core 205 per FIG. 2A-2B, for example. A gasket 601 may be usedto seal the heat exchanger assembly 600 to a partition of the closedcontainer. An internal 602 fan shroud and an external fan shroud 603cover the first and second fans (not shown). The shroud protects the fanblades and directs air across the plurality of surfaces. Each fan shroud602, 603 has a corresponding fan guard 607, 608 held to an opening inthe shrouds with fasteners such as nuts 609 a, 609 b, 609 c and bolts604 a, 604 b, 604 c, for example. The shrouds are connected to thecore(s) 605 and optional gasket 601 with attachments 610 a, 610 b, 610c. FIG. 6B is similar to FIG. 6A. FIG. 6B includes the fans 618 a, 618 bsurrounded by fan shrouds 602, 603, respectively. If fan(s) are notemployed, the corresponding fan shroud(s) need not be installed.

The first and/or second plurality of surfaces 106, 108 and 206, 208shown in FIGS. 1 and 2, respectively, may be fins, pins, pegs, or anycombination thereof. The first and/or second plurality of surfaces areconfigured to be attached to the core(s) 700 (e.g., interior and/orexterior cores 105, 107 or central core 205) in any combination.Preferably, a straight configuration as shown in FIG. 7A may be used;however, different variables and parameters may dictate or suggestalternative configurations. For example, configurations may be arrangedas angled (FIGS. 7B and 7F), flared (FIG. 7C), offset (FIG. 7G), combo(FIG. 7E) or random (FIG. 7D). Of course, many other examples arecontemplated and this disclosure is not limited to the examples shown inFIGS. 7A-7E.

A graph comparing performance versus size of selected flush-mounted heatexchangers is shown in FIG. 8. Dissipated heat, expressed in watts, isrepresented along the y axis and volume, expressed in cubic meters, istracked along the x axis. Current flush mount cooling units, such asheat pipes, are represented by circular data points and shown viaextrapolated trend line 800. The heat exchanger assembly, includingvarious embodiments of the subject invention, are represented by squareand triangular data points. Specifically, the square data pointsrepresent low cost snapped fins (i.e., plurality of surfaces) while thetriangular data points represent an extruded method of fin manufacture.Extrapolated trend line 801 summarizes snapped and extruded finsincluding embodiments of the present invention. Comparing the slopes ofthe extrapolated trend lines 800 and 801, it is clear that the heatexchanger assembly 801 dissipates heat relatively quickly given itssize.

FIG. 9 is a is a graphical representation showing performance versusmonetary cost comparison of selected flush-mounted heat exchangers.Dissipated heat, expressed in watts, is represented along the y axis andcost, expressed in U.S. dollars, is tracked along the x axis. Currentflush mount cooling units, such as heat pipes, are represented bycircular data points and shown via extrapolated trend line 900. The heatexchanger assembly, including various embodiments of the subjectinvention, are represented by square and triangular data points. Similarto FIG. 8 described above, the square data points specify low costsnapped fins (i.e., plurality of surfaces) while the triangular datapoints represent an extruded method of fin manufacture. A system usingextruded manufacturing techniques offers some advantages but it isgenerally more expensive. Extrapolated trend line 901 summarizes snappedand extruded fins including embodiments of the present invention.Comparing the slopes of the extrapolated trend lines 900 and 901, theheat exchanger assembly 901 (of which many embodiments are disclosedherein) works well to quickly dissipate heat and is much less expensiveto manufacture. The simulation data depicted in FIGS. 8 and 9quantitatively reflect the efficiency and cost effectiveness of someembodiments of the heat exchanger assembly disclosed herewith.

It is also understood that the examples and embodiments described hereinare for illustrative purposes only and that various modifications orchanges in light thereof will be suggested to persons skilled in the artand are to be included within the spirit and purview of this applicationand scope of the appended claims.

The previously described embodiments of the subject invention have manyadvantages, including an inexpensive, reliable, versatile, and efficientheat exchanger assembly and method that effectively removes heat fromenclosures. Specific advantages include saves power, reduces, operatingcosts, resists performance degradation, increases life span, reducesintroduction of contaminants, mitigates of hot spots, compact,lightweight design, eliminates dangerous chemicals or cooling fluids,environmentally safe, and easy installation in a wide variety oflocations and orientations.

The use of the terms “a” and “an” and “the” and similar referents in thecontext of describing the invention (especially in the context of thefollowing claims) are to be construed to cover both the singular and theplural, unless otherwise indicated herein or clearly contradicted bycontext. The terms “comprising,” “having,” “including,” and “containing”are to be construed as open-ended terms (i.e., meaning “including, butnot limited to,”) unless otherwise noted. The term “connected” is to beconstrued as partly or wholly contained within, attached to, or joinedtogether, even if there is something intervening. Recitation of rangesof values herein are merely intended to serve as a shorthand method ofreferring individually to each separate value falling within the range,unless otherwise indicated herein, and each separate value isincorporated into the specification as if it were individually recitedherein. All methods described herein can be performed in any suitableorder unless otherwise indicated herein or otherwise clearlycontradicted by context. The use of any and all examples, or exemplarylanguage (e.g., “such as”) provided herein, is intended merely to betterilluminate embodiments of the invention and does not pose a limitationon the scope of the invention unless otherwise claimed. No language inthe specification should be construed as indicating any non-claimedelement as essential to the practice of the invention.

As used in this specification, an “isolated environment” generallyincludes an “enclosure”, “container”, “cabinet”, “cage”, “closet”,“room” or “building” that has a defined interior with a substantiallyairtight seal from the defined exterior.

Preferred embodiments of this invention are described herein, includingthe best mode known to the inventors for carrying out the invention.Variations of those preferred embodiments may become apparent to thoseof ordinary skill in the art upon reading the foregoing description. Theinventors expect skilled artisans to employ such variations asappropriate, and the inventors intend for the invention to be practicedotherwise than as specifically described herein. Accordingly, thisinvention includes all modifications and equivalents of the subjectmatter recited in the claims appended hereto as permitted by applicablelaw. Moreover, any combination of the above-described elements in allpossible variations thereof is encompassed by the invention unlessotherwise indicated herein or otherwise clearly contradicted by context.

All references, including publications, patent applications, andpatents, cited herein are hereby incorporated by reference to the sameextent as if each reference were individually and specifically indicatedto be incorporated by reference and were set forth in its entiretyherein.

Although embodiments of the invention have been described inconsiderable detail with reference to certain preferred versionsthereof, other embodiments are possible. Therefore, the spirit and scopeof the appended claims should not be limited to the descriptions of theembodiments above.

1.-14. (canceled)
 15. A method of removing heat from an isolatedenvironment, the method comprises: affixing a heat exchanger assembly toa partition of an isolated environment; wherein the heat exchangerassembly comprises: a first plurality of fins, and a second plurality offins that are provided opposite the first plurality of fins such thatthe first plurality of fins are in thermal contact with the secondplurality of fins across a solid substrate core; at least one first fanoperatively connected to the solid substrate core and the firstplurality of fins; and at least one second fan operatively connected tothe solid substrate core and the second plurality of fins; supplyingpower to the at least one first fan and the at least one second fan;using the at least one first fan to push ambient air inside the isolatedenvironment across the first plurality of fins; and using the at leastone second fan to push ambient air outside the isolated environmentacross the second plurality of fins so that conductive heat transferfrom the first plurality of fins to the second plurality of fins removesheat from the isolated environment during use without the air outsidethe isolated environment mixing with the air inside the isolatedenvironment.
 16. The method of claim 15, wherein the ambient air insidethe isolated environment is warmer than the ambient air outside theisolated environment.
 17. The method of claim 15, further comprisingutilizing a programmable thermostat operably attached to the heatexchanger assembly to control supply of power to at least one of the atleast one first fan or the at least one second fan according toprogrammed temperature settings.
 18. The method of claim 15, wherein theheat exchanger assembly substantially reduces temperature gradientsinside the isolated environment.
 19. The method of claim 15, furthercomprising attaching a fan shroud to each of the at least one first andsecond fans, the fan shroud configured to channel air over, between,and/or around the first and second plurality of fins, respectively. 20.A heat exchanger assembly operable to transfer heat from inside airlocated inside a closed container to outside air located outside theclosed container, the heat exchanger assembly comprising: an interiorthermal conductor comprising a first plurality of surfaces joined to afirst side of a central core, wherein the first plurality of surfacesare spaced apart from one another; and an exterior thermal conductorcomprising a second plurality of surfaces joined to a second side of thecentral core, wherein the second plurality of surfaces are spaced apartfrom one another; and wherein a thermal path is defined from the firstplurality of surfaces to the second plurality of surfaces and whereinthe inside air does not mix with the outside air during use.
 21. Themethod of claim 17, comprising programming the programmable thermostatby using an electronics device via a wireless connection.
 22. A methodof cooling air within a closed container, the method comprising:operating a first fan to move air within a closed container across afirst plurality of surfaces that are spaced apart from one another;operating a second fan to move air exterior to the closed containeracross a second plurality of surfaces that are spaced apart from oneanother; and transferring heat from the first plurality of surfaces tothe second plurality of surfaces solely via conductive heat transfer.23. The method of claim 22, wherein the transferring of the heat fromthe first plurality of surfaces to the second plurality of surfacessolely via conductive heat transfer comprises: transferring the heatfrom the first plurality of surfaces to an interior core attached to thefirst plurality of surfaces; transferring the heat from the interiorcore to an exterior core; and transferring the heat from the exteriorcore to the second plurality of surfaces, the exterior core beingattached to the second plurality of surfaces.
 24. The method of claim23, wherein the transferring of the heat from the interior core to theexterior core comprises: transferring the heat from the interior core anexterior wall of the closed container through an interior side of theexternal wall; and transferring the heat from the external wall to theexterior core through an exterior side of the external wall.
 25. Themethod of claim 24, further comprising: attaching the interior core tothe exterior wall; and attaching the exterior core to the exterior wall.26. The method of claim 23, wherein: the first plurality of surfaces isattached to the interior core in any combination of straight, flared,angled, offset, or random arrangement; and the second plurality ofsurfaces is attached to the exterior core in any combination ofstraight, flared, angled, offset, or random arrangement.
 27. The methodof claim 22, wherein the first plurality of surfaces and/or the secondplurality of surfaces comprise fins, pins, pegs, or any combinationthereof.
 28. The method of claim 22, wherein the first plurality ofsurfaces are at least 0.04 inches thick and the second plurality ofsurfaces are at least 0.04 inches thick.
 29. The method of claim 22,wherein: the first fan has a capacity of at least 50 cubic feet perminute; and the second fan has a capacity of at least 50 cubic feet perminute.
 30. The method of claim 22, further comprising utilizing aprogrammable thermostat to control supply of power to the first fan andthe second fan according to programmed temperature settings.
 31. Themethod of claim 30, comprising programming the programmable thermostatby using an electronics device via a wireless connection.